Lucas TVS

Padi, Chennai - 600050

Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Free from Proper

Item not Manufacturing Incoming
Appearance Crack,Scratch, Visual not ok 5 3 instruction to 5 75
produce defect inspection report
pitted & Dents. supplier t.c

Item not Raw material Incoming Inspection

Dia 17.50 ± 0.1 Size variation 5 3 5 75
10) Incoming produce defect inspection parameters
Inspection
Material Receipt.
MTC verified,
Colour code
Without colour third party
Not sutaible identified on rod
Material EN8M Grrade mix up 8 code, all material 2 inspection, 5 80
for production & kept in seprate
put in one rack colour coding
rack
decide

Item not Raw material Incoming Inspection

OD 17.40/17.60 Size variation 5 3 5 75
produce defect inspection parameters

Tool wear, collat Cleaning of

First 5 PCS
Item not worn Out, Chip Collat & Collat
Approval/
U/S moved to 5 Exits Between 3 change 6 90
Process
next opr'n Collat & Work frequency
Inspection
T.Length 159.30/159.70 PCS decide
20) Blank Cutting Traub A25
Correct setting, First 5 PCS
Stopper losse &
Fitment Red bin Approval/
O/S 5 setting parts mix 3 6 90
Problem provide on Process
up
machine Inspection
First 5 PCS
Resharp of tool
Unable to Approval/
Chamfer Burr Remove U/O 6 Tool wear 3 after fixed 6 108
clamp Process
interval
Inspection
Incorrect Position Resharp of tool
First 5 PCS
of Tool Towards after fixed
Free Approval/
U/S 5 Work Pcs, Tool 3 interval, 5 75
Assemble Process
Blunt,Stopper Stopper proper
Inspection
T. Length 171.90/172.10 loose tight
First 5 PCS
Incorrect Position Resharp of tool
Unable Approval/
O/S 5 of Tool Towards 4 after fixed 5 100
Assemble Process
Work Pcs interval
Inspection

First 5 PCS
Change of
Unable Approval/
U/S 4 Center Broken 3 center after 5 60
Assemble Process
fixed interval
Inspection
Center 4.0/4.20

First 5 PCS
Change of
Free Approval/
O/S 5 Center Broken 4 center after 5 100
Assemble Process
fixed interval
Inspection
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Incorrect Position Resharp of tool

First 5 PCS
of Tool Towards after fixed
Free Approval/
U/S 4 Work Pcs, Tool 3 interval, 6 72
Assemble Process
Blunt,Stopper Stopper proper
Inspection
Dim. 16.23/16.37 loose tight

First 5 PCS
Incorrect Position Resharp of tool
Unable Approval/
O/S 4 of Tool Towards 3 after fixed 5 60
Assemble Process
Work Pcs interval
Inspection
First 5 PCS
Incorrect position Tool resharp
Unable Approval/
U/S 6 of tool towards 3 After fixed 5 90
Assemble Process
workpice interval
Inspection
Chamfer Dia 15.90/16.10
Incorrect position First 5 PCS
Tool resharp
Unable of tool towards Approval/
O/S 5 3 After fixed 6 90
Assemble workpice, Tool Process
interval
wear Inspection
First 5 PCS
Incorrect position Tool resharp
Unable Approval/
U/S 6 of tool towards 3 After fixed 5 90
Assemble Process
workpice interval
Inspection
30) Turning 1st Groove Dia 11.49/11.63
Incorrect position First 5 PCS
Oper.(Turning & Traub A25 Tool resharp
Unable of tool towards Approval/
Drilling) O/S 5 3 After fixed 6 90
Assemble workpice, Tool Process
interval
wear Inspection

Incorrect Position Resharp of tool

First 5 PCS
of Tool Towards after fixed
Unable Approval/
U/S 5 Work Pcs, Tool 3 interval, 5 75
Assemble Process
Blunt,Stopper Stopper proper
Inspection
Groove Width 2.20/2.40 loose tight

First 5 PCS
Incorrect Position Resharp of tool
Free Approval/
O/S 5 of Tool Towards 4 after fixed 5 100
Assemble Process
Work Pcs interval
Inspection
First 5 PCS
Incorrect position Tool resharp
Free Approval/
U/S 5 of tool towards 3 After fixed 6 90
Assemble Process
workpice interval
Inspection
Dia 13.10/13.20
Incorrect position First 5 PCS
Tool resharp
Unable of tool towards Approval/
O/S 6 3 After fixed 5 90
Assemble workpice, Tool Process
interval
wear Inspection

Incorrect position First 5 PCS

Tool resharp
Fitment of insert towards Approval/
Angle 30° Angle Not OK 5 3 after fixed 5 75
Problem workpice, Insert Process
interval
Blunt Inspection
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

First 5 PCS
Incorrect position Tool resharp
Free Approval/
U/S 5 of tool towards 3 After fixed 6 90
Assemble Process
workpice interval
Inspection
Ch. Dia 10.65/10.79
Incorrect position First 5 PCS
Tool resharp
Unable of tool towards Approval/
O/S 6 3 After fixed 5 90
Assemble workpice, Tool Process
interval
wear Inspection

Cleaning of
Collat Worn Out,
Collat & Collat
Chip Exits Inprocess
Concentricity 01/A O/S Runout More 5 4 change 5 100
Between Collat & Inspection
frequency
Work PCS
decide

Incorrect Position of Resharp of tool

Tool Towards Work after fixed interval, First 5 PCS Approval/
U/S Fitment Problem 5 3 5 75
Pcs, Tool Stopper proper Process Inspection
Blunt,Stopper loose tight
T. Length 171.42/171.58

Incorrect Position of
Resharp of tool First 5 PCS Approval/
O/S Fitment Problem 5 Tool Towards Work 4 5 100
after fixed interval Process Inspection
Pcs

Incorrect Position of Resharp of tool

Tool Towards Work after fixed interval, First 5 PCS Approval/
U/S Fitment Problem 4 3 5 60
Pcs, Tool Stopper proper Process Inspection
Blunt,Stopper loose tight
Length 146.60/146.80

Incorrect Position of
Resharp of tool First 5 PCS Approval/
O/S Fitment Problem 3 Tool Towards Work 4 6 72
after fixed interval Process Inspection
Pcs

Incorrect position of Insert change First 5 PCS Approval/

U/S Free Assemble 6 3 5 90
tool towards workpice After fixed interval Process Inspection

40) Turning 2nd Dia 9.80/10.0

Oper.(Turning & TRAUB M/C
Drilling)
Incorrect position of
Tool resharp After First 5 PCS Approval/
O/S Unable Assemble 5 tool towards 3 6 90
fixed interval Process Inspection
workpice, Tool wear
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
40) Turning 2nd D
Core team:
Oper.(Turning & Mr. Sanjay
TRAUB M/C Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process
Drilling) l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Change of Center
First 5 PCS Approval/
U/S Free Assemble 5 Center Broken 3 After Fixed 5 75
Process Inspection
Interval

Center 4.0/4.20

Change of Center
First 5 PCS Approval/
O/S Unable Assemble 4 Center Broken 3 After Fixed 5 60
Process Inspection
Interval

Incorrect position of Insert change First 5 PCS Approval/

U/S Free Assemble 5 3 5 75
tool towards workpice After fixed interval Process Inspection

Chamfer 0.90/1.10×45°

Incorrect position of
Tool resharp After First 5 PCS Approval/
O/S Unable Assemble 4 tool towards 3 5 60
fixed interval Process Inspection
workpice, Tool wear

Collat Worn Out, Chip Cleaning of Collat

Concentricity 0.10 O/S Runout More 5 Exits Between Collat 4 & Collat change Inprocess Inspection 5 100
& Work PCS frequency decide

Wheel dressing, Tool Life Monitoring ,

Glazing of grinding
Part not move for coolant level Sensor Cleaning Point
U/S 6 wheel & coolant flow 3 5 90
next operation gauge sensor Add In Preventive
pressure low
clean Maintenance Sheet

Dia 12.88/12.90

Incorrect setting,
Correct setting, Inprocess Inspection,
Part not move for setting part mix up,
50 ) Centerless C.L.G M/C O/S 7 2 Red bin provide on Setting Approval, 5 70
next operation coolant flow pressure
machine Rejection Sheet
low

Wheel dressing, Tool Life Monitoring ,

Grinding Wheel not Glazing of grinding
Part not move for coolant level Sensor Cleaning Point
Appearance touch on face & flat Visual not ok 5 wheel & coolant flow 4 5 100
next operation gauge sensor Add In Preventive
on DIA not allowed pressure low
clean Maintenance Sheet

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Dim. 78.0/78.10

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Incorrect position of
Part not move for Insert change First 5 PCS Approval/
U/S 5 insert towards 4 5 100
next operation After fixed interval Process Inspection
workpice

Dim. 121.02/121.12

Incorrect position of
Part not move for Insert change First 5 PCS Approval/
O/S 5 insert towards 3 5 75
next operation After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Solder Length 146.15/146.25

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 4 insert towards 3 6 72
After fixed interval Process Inspection
workpice

Dim. 2.60/2.70

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 4 insert towards 3 5 60
After fixed interval Process Inspection
workpice

Incorrect position of
insert towards Insert change First 5 PCS Approval/
U/S Free Assembly 5 3 6 90
workpice, Insert After fixed interval Process Inspection
Blunt

Dia 17.005/17.012

Incorrect position of
insert towards Insert change First 5 PCS Approval/
O/S Unable Assemble 4 3 5 60
workpice, Insert After fixed interval Process Inspection
Blunt

Incorrect position of
Unable to insert towards Insert change First 5 PCS Approval/
Angle 5°± 30' Angle not ok 5 3 5 75
assemble workpice, Insert After fixed interval Process Inspection
Blunt
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Incorrect position of
insert towards Insert change First 5 PCS Approval/
U/S Free Assembly 6 4 5 120
workpice, Insert After fixed interval Process Inspection
Blunt

Dia 16.90/16.92

Incorrect position of
insert towards Insert change First 5 PCS Approval/
O/S Unable Assemble 5 3 5 75
workpice, Insert After fixed interval Process Inspection
Blunt

Incorrect position of
insert towards Insert change First 5 PCS Approval/
U/S Free Assembly 5 3 6 90
workpice, Insert After fixed interval Process Inspection
Blunt

Dia 15.005/15.012

Incorrect position of
insert towards Insert change First 5 PCS Approval/
O/S Unable Assemble 4 3 6 72
workpice, Insert After fixed interval Process Inspection
Blunt

Incorrect position of
insert towards Insert change First 5 PCS Approval/
U/S Free Assembly 5 3 6 90
workpice, Insert After fixed interval Process Inspection
Blunt

Dia 8.97/8.98

Incorrect position of
insert towards Insert change First 5 PCS Approval/
O/S Unable Assemble 4 3 6 72
workpice, Insert After fixed interval Process Inspection
60 ) CNC Turning CNC M/C
Blunt

Jaw Worn Out, Chip Cleaning of Jaw,

Concentricity 0.05/A O/S Runout More 5 Exits Between Jaw & 4 Periodicaly Boring Inprocess Inspection 5 100
Work PCS of Jaw

Incorrect position of
insert towards Insert change First 5 PCS Approval/
U/S Free Assembly 5 4 5 100
workpice, Insert After fixed interval Process Inspection
Blunt

Chamfer Dia. 12.06/12.16

Incorrect position of
insert towards Insert change First 5 PCS Approval/
O/S Unable Assemble 5 3 5 75
workpice, Insert After fixed interval Process Inspection
Blunt
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Incorrect position of
insert towards Insert change First 5 PCS Approval/
U/S Free Assembly 5 4 5 100
workpice, Insert After fixed interval Process Inspection
Blunt

Groove Dia 7.95/8.05

Incorrect position of
insert towards Insert change First 5 PCS Approval/
O/S Unable Assemble 5 3 5 75
workpice, Insert After fixed interval Process Inspection
Blunt

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Groove Dia 16.30/16.40

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Groove Width 1.35/1.55

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Tapper Length 2.10/3.40

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Groove Width 1.45/1.55

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Dim. 2.50/2.60

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Dim. 0.65/0.85

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice

Wheel dressing, Tool Life Monitoring ,

Glazing of grinding
U/S Part not move 5 • wheel & coolant flow 3
pressure low
coolant level
gauge sensor
Sensor Cleaning Point
Add In Preventive
5 75
clean Maintenance Sheet

Dia 15.005/15.012

Incorrect setting,
Correct setting, Inprocess Inspection,
O/S Part not move 6 • setting part mix up,
coolant flow pressure
2 Red bin provide on Setting Approval,
machine Rejection Sheet
5 60
low

70) Cylinderical
C.L.G M/C Wheel dressing, Tool Life Monitoring ,
Grinding Glazing of grinding
U/S Part not move 5 • wheel & coolant flow 3
pressure low
coolant level
gauge sensor
Sensor Cleaning Point
Add In Preventive
5 75
clean Maintenance Sheet

Dia 16.985/16.990

Incorrect setting,
Correct setting, Inprocess Inspection,
O/S Part not move 6 • setting part mix up,
coolant flow pressure
2 Red bin provide on Setting Approval,
machine Rejection Sheet
5 60
low

Flat and Tapper not Job driver wear out,

Job driver life
Appearnce allowed, Dent not Visual not ok Unable assembly 6 grinding wheel touch 3 Process Inspection 5 90
monitoring
allowed on face

Roll as per specific Knurling die life

Knurling Pitch 1.16 Pitch 90 Tooth Angle not ok Not Proper Fitting 6 Roll Problem 2 5 60
size monitoring

Pressure
Pre Dim. Under size,
monitoring &
Stoper not ok & Setting part check &
U/S Free Assemble 3 3 checked by 5 45
pressure not as per Inprocess Inspection
operator during
specification
maching

Dim. 2.30/2.70

Pressure
Pre Dim. Over size,
monitoring &
Stoper not ok & Setting part check &
O/S Unable Assemble 4 3 checked by 5 60
pressure not as per Inprocess Inspection
operator during
specification
maching
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Pressure
Pre Dim. Under size,
monitoring &
Stoper not ok, Setting part check &
U/S Free Assemble 5 3 checked by 5 75
Pressure not as per Inprocess Inspection
operator during
specification
maching

Dim. 78.12/78.28

Pressure
Pre Dim. Over size,
monitoring &
Stoper not ok, Setting part check &
O/S Unable Assemble 6 4 checked by 5 120
Pressure not as per Inprocess Inspection
operator during
specification
maching

80) Knurling Rolling M/C Pressure

Pre Dim. Under size,
monitoring &
Stoper not ok, Setting part check &
U/S Free Assemble 4 3 checked by 5 60
Pressure not as per Inprocess Inspection
operator during
specification
maching

Dim. 2.82/2.98

Pressure
Pre Dim. Over size,
monitoring &
Stoper not ok, Setting part check &
O/S Unable Assemble 4 2 checked by 6 48
Pressure not as per Inprocess Inspection
operator during
specification
maching

Pressure
Pre Knurling Dia
monitoring &
Under Size & Setting part check &
U/S Free Assemble 4 3 checked by 6 72
Pressure not as per Inprocess Inspection
operator during
specification
maching

Knurling Dia 17.30/17.38

Pressure
Pre Knurling Dia
monitoring &
Under Size & Setting part check &
O/S Unable Assemble 5 3 checked by 6 90
Pressure not as per Inprocess Inspection
operator during
specification
maching

Rough Knurling or
Cutter Wear & OGS & WI display
Appearnce double knurling not Visual not ok Fitment Problem 6 3 Inprocess Inspection 5 90
Operator negligence on machine
allowed

Fixture as per Fixture life

Angle 90° Angle not ok Fitment Problem 5 Fixture not ok 3 5 75
specific size monitoring

Tool life
U/S Free Assemble 4 Cutter Broken & wear 2 Inprocess Inspection 6 48
monitoring

Dim. 9.45/9.59 Cutter MOP large,

play in spindal & Tool life Monitoring
Setting part check &
O/S Fitment Problem 3 Incorrect position of 2 & Daily machine 6 36
Inprocess Inspection
cutter towards check sheet
workpice
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N
Tool life
U/S Fitment Problem 4 Cutter wear 3 Inprocess inspection 6 72
monitoring

Width 2.33/2.43
Tool life Monitoring
Spindal Out & Cutter Setting part check &
O/S Free Assemble 4 3 & Daily machine 6 72
thickness large Inprocess Inspection
check sheet

Tool life
U/S Fitment Problem 4 Cutter wear 3 Inprocess inspection 6 72
monitoring

Width 3.14/3.18
Tool life Monitoring
Spindal Out & Cutter Setting part check &
O/S Free Assemble 4 3 & Daily machine 6 72
thickness large Inprocess Inspection
check sheet

Cutter Wear, Tool life

Incorrect position of Monitoring, Daily
U/S Fitment Problem 5 cutter towards 4 machine check Inprocess Inspection 5 100
workpice & sheet, OGS & WI
negligence display on machine

Length 32.25/32.75

Incorrect position of
Correct setting, Inprocess Inspection,
cutter towards
O/S Free Assemble 5 4 Red bin provide on Setting Approval, 5 100
workpice & stopper
machine Rejection Sheet
loose

90 ) Milling + Key Way Milling M/C

Cutter Wear, Tool life

Incorrect position of Monitoring, Daily
U/S Fitment Problem 5 cutter towards 4 machine check Inprocess Inspection 5 100
workpice & sheet, OGS & WI
negligence display on machine

Length 28.61/28.81

Incorrect position of
Correct setting, Inprocess Inspection,
cutter towards
O/S Free Assemble 5 4 Red bin provide on Setting Approval, 5 100
workpice & stopper
machine Rejection Sheet
loose

Cutter Wear, Tool life

Incorrect position of Monitoring, Daily
U/S Unable Assemble 5 cutter towards 4 machine check Inprocess Inspection 5 100
workpice & sheet, OGS & WI
negligence display on machine

Depth 3.28/3.48

Correct setting, Inprocess Inspection,

Incorrect position of
O/S Free Assemble 5 4 Red bin provide on Setting Approval, 5 100
cutter
machine Rejection Sheet
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Cutter Wear, Tool life

Incorrect position of Monitoring, Daily
U/S Unable Assemble 6 cutter towards 3 machine check Inprocess Inspection 5 90
workpice & sheet, OGS & WI
negligence display on machine

Cutter Dia 101.40/101.60

Incorrect position of
Correct setting, Inprocess Inspection,
cutter towards
O/S Free Assemble 5 3 Red bin provide on Setting Approval, 5 75
workpice & stopper
machine Rejection Sheet
loose

Pressure
Pre staking Dia under monitoring &
Setting part check &
U/S Free Assembly 3 size & Pressure not 3 checked by 5 45
Inprocess Inspection
as per specification operator during
maching

Dia 9.12/9.17

Pressure
Pre staking Dia Over monitoring &
Setting part check &
O/S Fitment Problem 4 size & Pressure not 3 checked by 5 60
Inprocess Inspection
as per specification operator during
maching

Fixture wear & Fixture validation

Fixture Validation
U/S Free Assembly 5 Pressure not as per 3 & Pressure 6 90
plan
specification monitoring

Width 5.90/6.30

Fixture not OK & Fixture validation

Fixture Validation
O/S Unable Assemble 5 Pressure not as per 3 & Pressure 6 90
plan
specification monitoring

Setting as per our

Stopper loose & Setting part check &
100 ) STAKING PRESS U/S Fitment Problem 4 3 requirement & Skill 6 72
Operator negligence Inprocess Inspection
Length 1.85/2.15 Matrix

Fixture Validation
O/S Fitment Problem 3 Stopper Wear 2 Fixture Validation 5 30
plan

Pressure
Pre staking Dia under monitoring &
Setting part check &
U/S Free Assembly 4 size & Pressure not 3 checked by 5 60
Inprocess Inspection
as per specification operator during
maching
Dia 8.97/8.99

Pressure
Pre staking Dia Over monitoring &
Setting part check &
O/S Fitment Problem 4 size & Pressure not 3 checked by 5 60
Inprocess Inspection
as per specification operator during
maching
Lucas TVS
Padi, Chennai - 600050
Process FMEA
Name M/S Shiv Shakti Automates Process Responsibility Sanjay Gupta FMEA Number SSA /TVS/PFMEA -26 22 2827
Model Year(s)/Vehicles(s):26 22 2827 Key Date: 14.06.2017 Prepared by: Amit Sangwan
D
Core team: Mr. Sanjay Gupta,Mrs. Arti Gupta, Mr. J.S.Ahlawat, Mr. Vijay Part
C Name: ShaftO FMEA
e Date (orig): 14.06.2017 (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Fixture as per Setting part check &

Angle 90°± 30' Angle Not OK Fitment Problem 5 Fixture problem 2 6 60
specific size Inprocess Inspection

Staking out, Double Fixture not ok & OGS & WI display

App. Visual not ok Fitment Problem 5 4 Inprocess Inspection 5 100
Staking operator negligence on machine

Roll as per specific Knurling die life

Thread M14x1.5-6g Angle Not OK Unable Assemble 5 Roller Problem 4 5 60
size monitoring

Pressure
Monitoring and
Pressure not as per Setting part check &
Length 16.20/16.40 O/S Unable Assemble 6 3 checked by 5 48
specification Inprocess Inspection
operator during
machine

Pressure
Pre rolling dia over Monitoring and
O/S Fitment Problem 4 size, Pressure not as 3 checked by Inprocess Inspection 5 100
per specification operator during
maching
110) Threading
M.D 13.80/13.85
Pressure
Pre rolling dia over Monitoring and
U/S Free Assembly 4 size, Pressure not as 3 checked by Inprocess Inspection 5 60
per specification operator during
maching

Rolling wheel face not

touch. Thread Stopper not ok & OGS & WI display
Appearnce Transit Damage Fitment Problem 4 2 Inprocess Inspection 6 48
damag, Crack, Dent Operator negligence on machine
not allowed

Wrong Check Of
120) PDI Manual All Perameter Fitment Problem 5 Unskill Inspector 4 Skill Matrix PDIR 5 100
Components

Separate Bin
Provide &
Material Mix Fitment Problem 4 Operator Negligence 3 Physical Verification 5 60
Component Wise
130) Packing Manual Manual Packing is Done

Transit Damage Fitment Problem 4 Packing Poor 3 Packing Standard Physical Verification 6 72

Form No.L21-0B Page of

 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Free from Proper

Item not Manufacturing Incoming
Appearance Crack,Scratch, Visual not ok 5 3 instruction to 5 75
produce defect inspection report
pitted & Dents. supplier t.c

Item not Raw material Incoming Inspection

Dia 17.50 ± 0.1 Size variation 5 3 5 75
10) Incoming produce defect inspection parameters
Inspection
Material Receipt.
MTC verified,
Colour code
Without colour third party
Not sutaible identified on rod
Material EN8M Grrade mix up 8 code, all material 2 inspection, 5 80
for production & kept in seprate
put in one rack colour coding
rack
decide

Item not Raw material Incoming Inspection

OD 17.40/17.60 Size variation 5 3 5 75
produce defect inspection parameters

Tool wear, collat Cleaning of

First 5 PCS
Item not worn Out, Chip Collat & Collat
Approval/
U/S moved to 5 Exits Between 3 change 6 90
Process
next opr'n Collat & Work frequency
Inspection
T.Length 159.30/159.70 PCS decide
20) Blank Cutting Traub A25
Correct setting, First 5 PCS
Stopper losse &
Fitment Red bin Approval/
O/S 5 setting parts mix 3 6 90
Problem provide on Process
up
machine Inspection
First 5 PCS
Resharp of tool
Unable to Approval/
Chamfer Burr Remove U/O 6 Tool wear 3 after fixed 6 108
clamp Process
interval
Inspection
Incorrect Position Resharp of tool
First 5 PCS
of Tool Towards after fixed
Free Approval/
U/S 5 Work Pcs, Tool 3 interval, 5 75
Assemble Process
Blunt,Stopper Stopper proper
Inspection
T. Length 171.90/172.10 loose tight
First 5 PCS
Incorrect Position Resharp of tool
Unable Approval/
O/S 5 of Tool Towards 4 after fixed 5 100
Assemble Process
Work Pcs interval
Inspection

First 5 PCS
Change of
Unable Approval/
U/S 4 Center Broken 3 center after 5 60
Assemble Process
fixed interval
Inspection
Center 4.0/4.20

First 5 PCS
Change of
Free Approval/
O/S 5 Center Broken 4 center after 5 100
Assemble Process
fixed interval
Inspection
 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Incorrect Position Resharp of tool

First 5 PCS
of Tool Towards after fixed
Free Approval/
U/S 4 Work Pcs, Tool 3 interval, 6 72
Assemble Process
Blunt,Stopper Stopper proper
Inspection
Dim. 16.23/16.37 loose tight

First 5 PCS
Incorrect Position Resharp of tool
Unable Approval/
O/S 4 of Tool Towards 3 after fixed 5 60
Assemble Process
Work Pcs interval
Inspection
First 5 PCS
Incorrect position Tool resharp
Unable Approval/
U/S 6 of tool towards 3 After fixed 5 90
Assemble Process
workpice interval
Inspection
Chamfer Dia 15.90/16.10
Incorrect position First 5 PCS
Tool resharp
Unable of tool towards Approval/
O/S 5 3 After fixed 6 90
Assemble workpice, Tool Process
interval
wear Inspection
First 5 PCS
Incorrect position Tool resharp
Unable Approval/
U/S 6 of tool towards 3 After fixed 5 90
Assemble Process
workpice interval
Inspection
30) Turning 1st Groove Dia 11.49/11.63
Incorrect position First 5 PCS
Oper.(Turning & Traub A25 Tool resharp
Unable of tool towards Approval/
Drilling) O/S 5 3 After fixed 6 90
Assemble workpice, Tool Process
interval
wear Inspection

Incorrect Position Resharp of tool

First 5 PCS
of Tool Towards after fixed
Unable Approval/
U/S 5 Work Pcs, Tool 3 interval, 5 75
Assemble Process
Blunt,Stopper Stopper proper
Inspection
Groove Width 2.20/2.40 loose tight

First 5 PCS
Incorrect Position Resharp of tool
Free Approval/
O/S 5 of Tool Towards 4 after fixed 5 100
Assemble Process
Work Pcs interval
Inspection
First 5 PCS
Incorrect position Tool resharp
Free Approval/
U/S 5 of tool towards 3 After fixed 6 90
Assemble Process
workpice interval
Inspection
Dia 13.10/13.20
Incorrect position First 5 PCS
Tool resharp
Unable of tool towards Approval/
O/S 6 3 After fixed 5 90
Assemble workpice, Tool Process
interval
wear Inspection

Incorrect position First 5 PCS

Tool resharp
Fitment of insert towards Approval/
Angle 30° Angle Not OK 5 3 after fixed 5 75
Problem workpice, Insert Process
interval
Blunt Inspection
 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

First 5 PCS
Incorrect position Tool resharp
Free Approval/
U/S 5 of tool towards 3 After fixed 6 90
Assemble Process
workpice interval
Inspection
Ch. Dia 10.65/10.79
Incorrect position First 5 PCS
Tool resharp
Unable of tool towards Approval/
O/S 6 3 After fixed 5 90
Assemble workpice, Tool Process
interval
wear Inspection

Cleaning of
Collat Worn Out,
Collat & Collat
Chip Exits Inprocess
Concentricity 01/A O/S Runout More 5 4 change 5 100
Between Collat & Inspection
frequency
Work PCS
decide

Incorrect Position of Resharp of tool

Tool Towards Work after fixed interval, First 5 PCS Approval/
U/S Fitment Problem 5 3 5 75
Pcs, Tool Stopper proper Process Inspection
Blunt,Stopper loose tight
T. Length 171.42/171.58

Incorrect Position of
Resharp of tool First 5 PCS Approval/
O/S Fitment Problem 5 Tool Towards Work 4 5 100
after fixed interval Process Inspection
Pcs

Incorrect Position of Resharp of tool

Tool Towards Work after fixed interval, First 5 PCS Approval/
U/S Fitment Problem 4 3 5 60
Pcs, Tool Stopper proper Process Inspection
Blunt,Stopper loose tight
Length 146.60/146.80

Incorrect Position of
Resharp of tool First 5 PCS Approval/
O/S Fitment Problem 3 Tool Towards Work 4 6 72
after fixed interval Process Inspection
Pcs

Incorrect position of Insert change First 5 PCS Approval/

U/S Free Assemble 6 3 5 90
tool towards workpice After fixed interval Process Inspection

40) Turning 2nd Dia 9.80/10.0

Oper.(Turning & TRAUB M/C
Drilling)
Incorrect position of
Tool resharp After First 5 PCS Approval/
O/S Unable Assemble 5 tool towards 3 6 90
fixed interval Process Inspection
workpice, Tool wear
 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
40) Turning 2nd D
Core team:
Oper.(Turning & TRAUB M/C Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process
Drilling) l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Change of Center
First 5 PCS Approval/
U/S Free Assemble 5 Center Broken 3 After Fixed 5 75
Process Inspection
Interval

Center 4.0/4.20

Change of Center
First 5 PCS Approval/
O/S Unable Assemble 4 Center Broken 3 After Fixed 5 60
Process Inspection
Interval

Incorrect position of Insert change First 5 PCS Approval/

U/S Free Assemble 5 3 5 75
tool towards workpice After fixed interval Process Inspection

Chamfer 0.90/1.10×45°

Incorrect position of
Tool resharp After First 5 PCS Approval/
O/S Unable Assemble 4 tool towards 3 5 60
fixed interval Process Inspection
workpice, Tool wear

Collat Worn Out, Chip Cleaning of Collat

Concentricity 0.10 O/S Runout More 5 Exits Between Collat 4 & Collat change Inprocess Inspection 5 100
& Work PCS frequency decide

Wheel dressing, Tool Life Monitoring ,

Glazing of grinding
Part not move for coolant level Sensor Cleaning Point
U/S 6 wheel & coolant flow 3 5 90
next operation gauge sensor Add In Preventive
pressure low
clean Maintenance Sheet

Dia 12.88/12.90

Incorrect setting,
Correct setting, Inprocess Inspection,
Part not move for setting part mix up,
50 ) Centerless C.L.G M/C O/S 7 2 Red bin provide on Setting Approval, 5 70
next operation coolant flow pressure
machine Rejection Sheet
low

Wheel dressing, Tool Life Monitoring ,

Grinding Wheel not Glazing of grinding
Part not move for coolant level Sensor Cleaning Point
Appearance touch on face & flat Visual not ok 5 wheel & coolant flow 4 5 100
next operation gauge sensor Add In Preventive
on DIA not allowed pressure low
clean Maintenance Sheet

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Dim. 78.0/78.10

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice
 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Incorrect position of
Part not move for Insert change First 5 PCS Approval/
U/S 5 insert towards 4 5 100
next operation After fixed interval Process Inspection
workpice

Dim. 121.02/121.12

Incorrect position of
Part not move for Insert change First 5 PCS Approval/
O/S 5 insert towards 3 5 75
next operation After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Solder Length 146.15/146.25

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 4 insert towards 3 6 72
After fixed interval Process Inspection
workpice

Dim. 2.65/2.75

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 4 insert towards 3 5 60
After fixed interval Process Inspection
workpice

Incorrect position of
U/S Free Assembly 5 • insert towards
workpice, Insert
3
Insert change First 5 PCS Approval/
After fixed interval Process Inspection
6 90
Blunt

Dia 17.004/17.012

Incorrect position of
O/S Unable Assemble 4 • insert towards
workpice, Insert
3
Insert change First 5 PCS Approval/
After fixed interval Process Inspection
5 60
Blunt

Incorrect position of
Unable to insert towards Insert change First 5 PCS Approval/
Angle 5°± 30' Angle not ok 5 3 5 75
assemble workpice, Insert After fixed interval Process Inspection
Blunt
 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Incorrect position of
insert towards Insert change First 5 PCS Approval/
U/S Free Assembly 6 4 5 120
workpice, Insert After fixed interval Process Inspection
Blunt

Dia 16.90/16.92

Incorrect position of
insert towards Insert change First 5 PCS Approval/
O/S Unable Assemble 5 3 5 75
workpice, Insert After fixed interval Process Inspection
Blunt

Incorrect position of
U/S Free Assembly 5 • insert towards
workpice, Insert
3
Insert change First 5 PCS Approval/
After fixed interval Process Inspection
6 90
Blunt

Dia 15.004/15.012

Incorrect position of
O/S Unable Assemble 4 • insert towards
workpice, Insert
3
Insert change First 5 PCS Approval/
After fixed interval Process Inspection
6 72
Blunt

Incorrect position of
insert towards Insert change First 5 PCS Approval/
U/S Free Assembly 5 3 6 90
workpice, Insert After fixed interval Process Inspection
Blunt

Dia 8.97/8.98

Incorrect position of
insert towards Insert change First 5 PCS Approval/
O/S Unable Assemble 4 3 6 72
workpice, Insert After fixed interval Process Inspection
60 ) CNC Turning CNC M/C
Blunt

Jaw Worn Out, Chip Cleaning of Jaw,

Concentricity 0.05/A O/S Runout More 5 Exits Between Jaw & 4 Periodicaly Boring Inprocess Inspection 5 100
Work PCS of Jaw

Incorrect position of
insert towards Insert change First 5 PCS Approval/
U/S Free Assembly 5 4 5 100
workpice, Insert After fixed interval Process Inspection
Blunt

Chamfer Dia. 12.06/12.16

Incorrect position of
insert towards Insert change First 5 PCS Approval/
O/S Unable Assemble 5 3 5 75
workpice, Insert After fixed interval Process Inspection
Blunt
 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Incorrect position of
insert towards Insert change First 5 PCS Approval/
U/S Free Assembly 5 4 5 100
workpice, Insert After fixed interval Process Inspection
Blunt

Groove Dia 7.95/8.05

Incorrect position of
insert towards Insert change First 5 PCS Approval/
O/S Unable Assemble 5 3 5 75
workpice, Insert After fixed interval Process Inspection
Blunt

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Groove Dia 16.30/16.40

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Groove Width 1.35/1.55

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Tapper Length 2.10/3.40

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Groove Width 1.45/1.55

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Dim. 2.50/2.60

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice
 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Incorrect position of
Insert change First 5 PCS Approval/
U/S Free Assembly 5 insert towards 4 5 100
After fixed interval Process Inspection
workpice

Dim. 0.65/0.85

Incorrect position of
Insert change First 5 PCS Approval/
O/S Unable Assemble 5 insert towards 3 5 75
After fixed interval Process Inspection
workpice

Roll as per specific Knurling die life

Knurling Pitch 1.16 Pitch 90 Tooth Angle not ok Not Proper Fitting 6 Roll Problem 2 5 60
size monitoring

Pressure
Pre Dim. Under size,
monitoring &
Stoper not ok & Setting part check &
U/S Free Assemble 3 3 checked by 5 45
pressure not as per Inprocess Inspection
operator during
specification
maching
Dim. 2.30/2.70

Pressure
Pre Dim. Over size,
monitoring &
Stoper not ok & Setting part check &
O/S Unable Assemble 4 3 checked by 5 60
pressure not as per Inprocess Inspection
operator during
specification
maching

70) Knurling Rolling M/C

 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Pressure
Pre Dim. Under size,
monitoring &
Stoper not ok, Setting part check &
U/S Free Assemble 5 3 checked by 5 75
Pressure not as per Inprocess Inspection
operator during
specification
maching

Dim. 78.12/78.28

Pressure
Pre Dim. Over size,
monitoring &
Stoper not ok, Setting part check &
O/S Unable Assemble 6 4 checked by 5 120
Pressure not as per Inprocess Inspection
operator during
specification
maching

70) Knurling Rolling M/C Pressure

Pre Dim. Under size,
monitoring &
Stoper not ok, Setting part check &
U/S Free Assemble 4 3 checked by 5 60
Pressure not as per Inprocess Inspection
operator during
specification
maching

Dim. 2.82/2.98

Pressure
Pre Dim. Over size,
monitoring &
Stoper not ok, Setting part check &
O/S Unable Assemble 4 2 checked by 6 48
Pressure not as per Inprocess Inspection
operator during
specification
maching

Pressure
Pre Knurling Dia
monitoring &
Under Size & Setting part check &
U/S Free Assemble 4 3 checked by 6 72
Pressure not as per Inprocess Inspection
operator during
specification
maching

Knurling Dia 17.30/17.38

Pressure
Pre Knurling Dia
monitoring &
Under Size & Setting part check &
O/S Unable Assemble 5 3 checked by 6 90
Pressure not as per Inprocess Inspection
operator during
specification
maching

Rough Knurling or
Cutter Wear & OGS & WI display
Appearnce double knurling not Visual not ok Fitment Problem 6 3 Inprocess Inspection 5 90
Operator negligence on machine
allowed

Fixture as per Fixture life

Angle 90° Angle not ok Fitment Problem 5 Fixture not ok 3 5 75
specific size monitoring

Tool life
U/S Free Assemble 4 Cutter Broken & wear 2 Inprocess Inspection 6 48
monitoring

Dim. 9.45/9.59 Cutter MOP large,

play in spindal & Tool life Monitoring
Setting part check &
O/S Fitment Problem 3 Incorrect position of 2 & Daily machine 6 36
Inprocess Inspection
cutter towards check sheet
workpice
 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N
Tool life
U/S Fitment Problem 4 Cutter wear 3 Inprocess inspection 6 72
monitoring

Width 2.33/2.43
Tool life Monitoring
Spindal Out & Cutter Setting part check &
O/S Free Assemble 4 3 & Daily machine 6 72
thickness large Inprocess Inspection
check sheet

Tool life
U/S Fitment Problem 4 Cutter wear 3 Inprocess inspection 6 72
monitoring

Width 3.14/3.18
Tool life Monitoring
Spindal Out & Cutter Setting part check &
O/S Free Assemble 4 3 & Daily machine 6 72
thickness large Inprocess Inspection
check sheet

Cutter Wear, Tool life

Incorrect position of Monitoring, Daily
U/S Fitment Problem 5 cutter towards 4 machine check Inprocess Inspection 5 100
workpice & sheet, OGS & WI
negligence display on machine

Length 32.25/32.75

Incorrect position of
Correct setting, Inprocess Inspection,
cutter towards
O/S Free Assemble 5 4 Red bin provide on Setting Approval, 5 100
workpice & stopper
machine Rejection Sheet
loose

80 ) Milling + Key Way Milling M/C

Cutter Wear, Tool life

Incorrect position of Monitoring, Daily
U/S Fitment Problem 5 cutter towards 4 machine check Inprocess Inspection 5 100
workpice & sheet, OGS & WI
negligence display on machine

Length 28.61/28.81

Incorrect position of
Correct setting, Inprocess Inspection,
cutter towards
O/S Free Assemble 5 4 Red bin provide on Setting Approval, 5 100
workpice & stopper
machine Rejection Sheet
loose

Cutter Wear, Tool life

Incorrect position of Monitoring, Daily
U/S Unable Assemble 5 cutter towards 4 machine check Inprocess Inspection 5 100
workpice & sheet, OGS & WI
negligence display on machine

Depth 3.28/3.48

Correct setting, Inprocess Inspection,

Incorrect position of
O/S Free Assemble 5 4 Red bin provide on Setting Approval, 5 100
cutter
machine Rejection Sheet
 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Cutter Wear, Tool life

Incorrect position of Monitoring, Daily
U/S Unable Assemble 6 cutter towards 3 machine check Inprocess Inspection 5 90
workpice & sheet, OGS & WI
negligence display on machine

Cutter Dia 101.40/101.60

Incorrect position of
Correct setting, Inprocess Inspection,
cutter towards
O/S Free Assemble 5 3 Red bin provide on Setting Approval, 5 75
workpice & stopper
machine Rejection Sheet
loose

Pressure
Pre staking Dia under monitoring &
Setting part check &
U/S Free Assembly 3 size & Pressure not 3 checked by 5 45
Inprocess Inspection
as per specification operator during
maching

Dia 9.12/9.17

Pressure
Pre staking Dia Over monitoring &
Setting part check &
O/S Fitment Problem 4 size & Pressure not 3 checked by 5 60
Inprocess Inspection
as per specification operator during
maching

Fixture wear & Fixture validation

Fixture Validation
U/S Free Assembly 5 Pressure not as per 3 & Pressure 6 90
plan
specification monitoring

Width 5.90/6.30

Fixture not OK & Fixture validation

Fixture Validation
O/S Unable Assemble 5 Pressure not as per 3 & Pressure 6 90
plan
specification monitoring

Setting as per our

Stopper loose & Setting part check &
90 ) STAKING PRESS U/S Fitment Problem 4 3 requirement & Skill 6 72
Operator negligence Inprocess Inspection
Length 1.85/2.15 Matrix

Fixture Validation
O/S Fitment Problem 3 Stopper Wear 2 Fixture Validation 5 30
plan

Pressure
Pre staking Dia under monitoring &
Setting part check &
U/S Free Assembly 4 size & Pressure not 3 checked by 5 60
Inprocess Inspection
as per specification operator during
maching
Dia 8.97/8.99

Pressure
Pre staking Dia Over monitoring &
Setting part check &
O/S Fitment Problem 4 size & Pressure not 3 checked by 5 60
Inprocess Inspection
as per specification operator during
maching
 Process FMEA
Name Process Responsibility FMEA Number
Model Year(s)/Vehicles(s): Key Date: Prepared by:
D
Core team: Part
C Name: O FMEA
e Date (orig): (Rev): 00 O
Process l Potential c t Action Resultsc D
Function Responsibility &
Potential S a Cause's)/ c Current Process Controls e R Recommended S c e R
Target Completion
Machine Potential Effect's) of e s Mechanism's) u c P Action's) Actions e u n P
Date
Requirements Description Product Characteristics Failure Mode Failure v s of Failure r Prevention Detection t N Taken v r t N

Fixture as per Setting part check &

Angle 90°± 30' Angle Not OK Fitment Problem 5 Fixture problem 2 6 60
specific size Inprocess Inspection

Staking out, Double Fixture not ok & OGS & WI display

App. Visual not ok Fitment Problem 5 4 Inprocess Inspection 5 100
Staking operator negligence on machine

Roll as per specific Knurling die life

Thread M14x1.5-6g Angle Not OK Unable Assemble 5 Roller Problem 4 5 60
size monitoring

Pressure
Monitoring and
Pressure not as per Setting part check &
Length 16.20/16.40 O/S Unable Assemble 6 3 checked by 5 48
specification Inprocess Inspection
operator during
machine

Pressure
Pre rolling dia over Monitoring and
O/S Fitment Problem 4 size, Pressure not as 3 checked by Inprocess Inspection 5 100
per specification operator during
maching
100) Threading
M.D 13.80/13.85
Pressure
Pre rolling dia over Monitoring and
U/S Free Assembly 4 size, Pressure not as 3 checked by Inprocess Inspection 5 60
per specification operator during
maching

Rolling wheel face not

touch. Thread Stopper not ok & OGS & WI display
Appearnce Transit Damage Fitment Problem 4 2 Inprocess Inspection 6 48
damag, Crack, Dent Operator negligence on machine
not allowed

Wrong Check Of
110) PDI Manual All Perameter Fitment Problem 5 Unskill Inspector 4 Skill Matrix PDIR 5 100
Components

Separate Bin
Provide &
Material Mix Fitment Problem 4 Operator Negligence 3 Physical Verification 5 60
Component Wise
120) Packing Manual Manual Packing is Done

Transit Damage Fitment Problem 4 Packing Poor 3 Packing Standard Physical Verification 6 72

Form No.L21-0B Page of

Legends : • Critical,0 Major, O/S - Over Size, U/S Under Size, M.D - Major Dia,
Prepared By Approved By